J&M 220 Operating And Maintenance Manual
MODEL 220
HYDRAULIC
IMPACT HAMMER
OPERATING AND MAINTENANCE MANUAL
J&M MODEL 220
SERIAL NUMBERS: 484002 AND ABOVE
OM-220-325-0296
HYDRAULIC IMPACT HAMMER
WITH MODEL 335 POWER PACK
J&M FOUNDATION
EQUIPMENT, LLC
SPECIALIZING IN PILE DRIVING EQUIPMENT
MODEL 220
HYDRAULIC
IMPACT HAMMER
MODEL 220
HYDRAULIC
IMPACT HAMMER
This manual was prepared to acquaint the owner, operator and serviceman with the
construction, operation and servicing of the J&M Model 220 Hydraulic Impact Pile Hammer
and the J&M Model 325 Power Unit. We strongly suggest that this manual be studied carefully
and understood by all personnel involved in operating or performing maintenance work on the
hammer. J&M equipment is engineered to provide reliable operation and a long servJ&M life
under normal operating conditions. Equipment reliability and service life can be improved by
following the maintenance procedures in this manual.
This manual is divided into seven sections- Introduction, General information, Preparation for
Operation, Operation, Maintenance, Trouble-Shooting and Ordering Parts.
The General Information section contains a brief description of the hammer and specification
information.
The Preparation for Operation section contains information about maintenance and other work
required before starting the hammer.
The Operation section includes general operating information plus details on hot and cold
weather operation.
The Maintenance & Adjustments section contains routine maintenance procedures and
instructions for making adjustments and repairs to the hammer.
The Trouble-Shooting section has suggestions for identifying and resolving operating
difficulties.
The Ordering Parts section contains information for ordering parts including parts drawings and
lists.
PREFACE
MODEL 220
HYDRAULIC
IMPACT HAMMER
MODEL 220
HYDRAULIC
IMPACT HAMMER
J&M, Foundation Equipment, LLC. (J&M) warrants new products sold by it to be free from
defects in material and workmanship for a period of 90 days after date of delivery to the first
user and subject to the following conditions: J&M’s obligation and liability under this warranty is
expressly limited to repairing or replacing, at J&M's option, any parts which appear to J&M
upon inspection to have been defective in material or workmanship. Such parts shall be
provided at no cost to the user at the business establishment of J&M or at the J&M distributor
of the product during regular working hours.
This warranty shall not apply to component parts or accessories of products not manufactured
by J&M and which carry the warranty of the manufacturer thereof or to normal maintenance
parts (such as filters).
Replacement or repair parts installed in the product covered by this warranty are warranted
only for the remainder of the warranty as if such parts were original components of said
product.
J&M's obligation under this warranty shall not include any transportation charges, costs of
installation, duty, taxes or any other charges whatsoever, or any liability for direct, indirect,
incidental, or consequential damage or delay.
If requested by J&M, products or parts for which a warranty claim is made are to be returned
transportation prepaid to J&M.
Any improper use, including operation after discovery of defective or worn parts, operation
beyond rated capacity, substitution of parts not approved by J&M or any alteration or repair by
others in such manner as is J&M's judgment affects the product materially and adversely shall
void the warranty.
For impact pile hammers, driving in excess of 10 blows per inch (set of 0.1 inch per blow) is
considered practical refusal. Driving in excess of 10 blows per inch for more than 6 inches of
driving or driving in excess of 20 blows per inch at all is considered improper use and will void
the hammer warranty.
For vibratory drivers, driving when penetration is less than 1" per minute is considered practical
refusal. Driving when penetration is less than 1" per minute for more then 5 minutes of driving
or driving at all when penetration is less than 1" per minute and amplitude is greater than
1" (vibrator and pile are bouncing) is considered improper use and will void the vibrator
warranty.
J&M makes no other warranty, expressed or implied, and makes no warranty of
merchantability or fitness for any particular purpose.
No employee or representative is authorized to change this warranty unless such change is
made in writing and signed by an officer of J&M.
J&M, LLC.
STANDARD WARRANTY
MODEL 220
HYDRAULIC
IMPACT HAMMER
I. GENERAL INFORMATION
A. General Description I-1
B. Major Components (line drawing) I-1
C. Specifications I-5
II. PREPARATION FOR OPERATION
A. General II-1
B. Safety Precautions II-1
C. Handling II-4
D. Connecting Crane Line To Hammer II-5
E. Attachment Of Lead Guides II-6
F. Attachment Of Drive Cap II-6
G. Mounting Hammer In Lead II-7
H. Connection Of Hydraulic Hoses II-8
I. Filling The Hammer Pressure Hose II-9
J. Filling Variable Stroke Cylinder Hoses II-10
K. Setting Variable Stroke Cylinder Pressure II-10
L. Fuel, Lubricating Oil And Grease II-11
III. OPERATING INSTRUCTIONS
A. Completion of Set-up and Maintenance III-2
B. Control Panel III-2
C. Starting And Warming Up The Engine III-3
D. Warming Hydraulic Oil III-3
E. Operation Of The Hammer III-4
1. Rated Hammer Energy III-4
2. Maximum blows per inch III-4
3. Stroke Control III-4
4. Stroke Setting III-5
F. Starting The Hammer III-6
G. Stopping The Hammer III-6
H. Single Blow Operation III-6
I. Emergency Stop III-6
J. Engine Shut Down III-6
K. Hot & Cold Weather Operation III-7
IV. MAINTENANCE AND ADJUSTMENTS
A. General IV-1
B. Maintenance - Daily IV-2
C. After Start-Up, Check The Following IV-3
D. Maintenance -Monthly IV-3
TABLE OF CONTENTS
PAGE
MODEL 220
HYDRAULIC
IMPACT HAMMER
TABLE OF CONTENTS
IV. MAINTENANCE AND ADJUSTMENTS (CONTINUED)
E. Maintenance - Every 4 Months IV-3
F. Annually IV-3
G. Severe Conditions IV-4
H. Lubrication IV-4
I. Hydraulic Oil IV-5
J. Capacities IV-7
K. Draining And Filling Hydraulic Reservoir IV-7
L. Changing The Hydraulic Return Filter Element IV-8
M. Setting Main Relief Valve IV-9
N. Setting Stroke Control (Clamp) Reli ef Valve IV-10
O. Tensioning Wire Ropes IV-10
P. Charging Accumulators IV-12
Q. Replacing Ram Connection IV-13
R. Bolt Torque Information IV-14
S. Checking & Replacing Recoil Dampener IV-15
T. Checking & Replacing Cushion Material IV-15
V. HYDRAULIC CIRCUITRY
A. Drive Pump V-1
B. Stroke Control Pump V-2
C. Other V-3
Hydraulic Schematic V-4
D. Hydraulic Components List V-5
VI. ELECTRICAL CIRCUITRY
A. Diesel Engine VI-1
B. Stroke Range Select VI-2
C. Hydraulic Hammer VI-2
D. Remote - Local Control VI-2
E. Engine Throttle VI-3
F. Tachometer VI-3
G. Other VI-3
Electrical Layout VI-4
Electrical Schematic VI-5
H. Electrical Components List VI-6
PAGE
MODEL 220
HYDRAULIC
IMPACT HAMMER
TABLE OF CONTENTS
VII. GENERAL DATA
A. Abbreviations VII-1
B. Screws And Bolts VII-2
C. Serial Number Locations VII-2
VIII. ORDERING PARTS
A. Procedure VIII-1
B. Fitting Description Key VIII-2
Fitting Description Selector Chart - SC1 VIII-3
C. Hose Description Code VIII-4
D. Parts Identification VIII-5
E. Miscellaneous Accessories VIII-48
F. Recommended Spare Parts VIII-51
G. Recommended Tightening Torque VIII-52
MODEL 220
HYDRAULIC
IMPACT HAMMER
I. GENERAL INFORMATION
A. GENERAL DESCRIPTION
The J&M Model 220 Hydraulic Hammer is a Free-Fall hammer. The ram is lifted by
the hydraulic actuator and then allowed to free-fall, impacting the pile. The hammer
has been designed to provide maximum flexibility by enabling the contractor to vary
the energy range of the hammer to suit job conditions. The 220 hammer design
incorporates an all hydraulic control system, with no electrical or electronic controls
used, to ensure reliability and field serviceability. Further, without the need for
vulnerable umbilical cords, this unit is readily adaptable to alternate hydraulic power
sources.
The 220 hammer is normally powered by the same Model 175 power unit that
powers J&M Vibratory Hammers and J&M Earth Augers. This permits the
contractor to use a single power unit on jobs where both the Impact Hammer and a
Vibratory Hammer or Auger are needed. The Hammer can also be powered by any
source providing the required flow, pressure, cooling and filtration. The 220
Hydraulic Hammer delivers 46,000 ft-lbs (6359.7 Kg-M) of energy at its full stroke of
4’-0” (1.2M) at a blow rate of 40 blows per minute.
B. MAJOR COMPONENTS
The hammer system consists of 8 major components (Fig. 1) page I-4:
Hydraulic Actuator
Ram
Guide Structure
Lifting Bale
Drive Cap
Controls
Interconnecting Hoses
Power Unit
Hydraulic Actuator
The hammer is driven by the hydraulic actuator. The actuator is coupled to the ram
using a shock absorbing, self aligning, connection. Hydraulic oil flows from the
power unit, at pressure, to the actuator which accelerates the ram upward.
Attached to the ram is a trip bar which activates a trip valve after the ram has risen
a predetermined distance. Activation of the trip valve stops the flow of oil to the
actuator. The ram then decelerates and free falls to impact the pile. Power unit
energy is stored in a hydraulic accumulator while the ram is falling.
I-1
MODEL 220
HYDRAULIC
IMPACT HAMMER
I. GENERAL INFORMATION
B. MAJOR COMPONENTS (CONTINUED)
Ram
The ram is a one piece high strength steel forging. The one piece construction of
the ram eliminates slack in the driving system and provides maximum energy
transfer to the pile. The one piece construction also eliminates the dangers of
structural failure known to exist in rams constructed of separate segments. High
performance, non-metallic, bearings, retained within the ram, prevent guide column
wear and reduces maintenance and lubrication requirements. The shock and
vibration, generated when the ram impacts the pile, are isolated from the hydraulic
actuator by an elastomeric, self aligning, coupling.
Guide Structure
The guide structure consists of tubular steel guide columns and connection plates.
The guide columns serve to guide the ram and provide the rigidity required to allow
the driving of batter piles. Guide columns, connecting plates and lifting bale are
held together by tensioned wire ropes which run from the base plate to the top of
the lifting bale. These cables provide a resilient means of connection and eliminate
the need for keys or bolted connections. The hammer is designed to fit in 26” x 8”
rail leads produced by J&M and other manufacturers. The connecting plates
provide mounting points for the lead guide rails necessary for J&M leads and
various other hammer guidance systems.
Lifting Bale
The lifting bale surrounds and protects the hydraulic actuator and hoses from
damage and is the attachment point for the lifting sheave. Two energy storing
hydraulic accumulators are mounted to, and protected by, the lifting bale.
Incorporated in the lifting bale design are the connection flanges for the hydraulic
supply hoses, and a shock absorbing hose support.
Drive Cap Assembly
Striking energy of the ram is transmitted to the pile through the three elements of the
drive cap assembly. The ram impacts the forged steel striker block which self aligns
and self centers within the lower connecting plate. Ram energy is transferred
through cushion material into the DCB-X drive cap base. The DCB-X serves to
retain the cushion material, Guide the piling, and adapt to various styles of J&M
piling inserts. Piling inserts adapt the hammer to most popular types of piling and
retain additional cushion material when required.
I-2
MODEL 220
HYDRAULIC
IMPACT HAMMER
I. GENERAL INFORMATION
B. MAJOR COMPONENTS (CONTINUED)
Controls
The hammer is controlled by a remote electric/hydraulic system in the power unit
which allows for both manual single blow operation or automatic continuous stroke
operation. The stroke of the ram can be varied between 12” (.3M) and 48” (1.2M),
on-the-fly, allowing control of the hammer energy to suit various types of piling and
soil conditions. Under continuous operation, the hammer will operate at 45 blows
per minute at the maximum energy setting. The blow rate will increase at lower
energy settings. Control of the continuous cycling of the hammer is fully hydraulic
(non-electric), operated by valves contained within the actuator assembly. No
maintenance of adjustment of these valves is normally required. The hammer can
be operated from the control panel at the power unit, the remote pendant control or
the radio remote control unit
Interconnecting Hoses
Hydraulic power is transmitted from the power unit to the hammer through 100 ft.
(30M) of steel braid reinforced hydraulic hoses (4). High pressure, threaded type,
quick disconnects on these hoses facilitate connection to the power unit without oil
loss. Dust covers are provided to keep disconnects clean when the hammer is
disconnected.
Power Unit
Power for the hammer is normally provided by a free-standing, Model 325, dieselhydraulic power unit. The Model 325 is powered by a Caterpillar 3306 engine which
develops 325 Hp at 2100 rpm. The totally enclosed power unit is mounted on a skid
type fuel tank sub-base, and has lockable doors. Central lifting of the power unit is
facilitated by an integral lifting bale. A control panel at the side of the unit contains
all the operating gages and controls. A common reservoir supplies hydraulic oil to
the main pump and the stroke control pump. Filtration and cooling means for the
hydraulic oil are incorporated within the power unit. Electro/hydraulic valves are
provided for hammer start/stop and stroke control. Pressure limiting valves are
included for all systems. Four hydraulic hoses connect the power unit to the Model
220 hammer. This power unit can also be crane mounted for ease of operation.
If the crane is capable of providing the required flow, pressure, cooling and filtration
to the hammer, it is possible to adapt it for hammer operation and eliminate the
power unit
I-3
MODEL 220
HYDRAULIC
IMPACT HAMMER
I. GENERAL INFORMATION
B. MAJOR COMPONENTS (CONTINUED)
SHEAVE
LIFTING BALE
HYD ACTUATOR ASM
CONTROL PANEL
CONTROL PENDANT
175 POWER UNIT
GUIDE STRUCTURE
TRIP BAR
HOSES
RAM
DRIVE CAP
INSERT
FIG 1
I-4
MODEL 220
HYDRAULIC
IMPACT HAMMER
I. GENERAL INFORMATION
C. SPECIFICATIONS
Working Specifications
Designation J&M Model 220
Maximum stroke 4'-0" (1.2 Meter)
Rated energy @ maximum stroke 88,000 ft-lbs (119kj)
Blow rate @ maximum stroke 45 bpm
Minimum stroke 1' (0.3 Meter)
Rated energy @ minimum stroke 11,500 ft-lbs (15 kN-m)
Blow rate @ minimum stroke 75 bpm
Weights and Dimensions
Ram weight 22,000 lbs (5,215 kg)
Hammer weight (bare)* 35,000 lbs (8,573 kg)*
Complete operating weight with cap*,** 41395 lbs (18776 kg)**
Length (bare)** 121-0" (6401mm)
Complete operating length with cap** 23'-7” (7188mm)**
Width (without guides) 32" (660 mm)
Depth 48" (1219mm)
Depth centerline to back 18" (457 mm)
Depth centerline to front 18" (457 mm)
Hydraulic hose length (standard) 150' (45 m)
*Weight includes one half of hydraulic hoses.
**Set up for 26" leads and 14" square concrete pile.
Power Unit
Designation J&M Model 325
Engine CAT 3306TA
Max. power 335 HP (250kW)
Operating speed 2100 rpm
Max. drive pressure 5,000 psi (345 bar)
Drive flow 87 gpm (330 lpm)
Stroke control pressure 4,300 psi (295 bar)
Stroke control flow 5.2 gpm (20 lpm)
Weight 9,600 lbs (4355 kg)*
Length 126" (320 cm)
Width 60" (152 cm)
Height 75.5" (192 cm)
I-5
MODEL 220
HYDRAULIC
IMPACT HAMMER
II. PREPARATION FOR OPERATION
A. GENERAL
When loading and unpacking the hydraulic hammer and accessories, use extreme
care. For your protection, make a thorough inspection of the unit immediately on
delivery. In case of any damage or shortage, notify the transit agent at once and
have the delivering carrier make a notation on the freight bill. Use timber, heavy
duty banding, etc to block ram movement during shipment.
(SEE SECTION II C FOR LIFTING INSTRUCTIONS)
B. SAFETY PRECAUTIONS
Safety is basically a matter of common sense. There are standard safety rules, but
each situation has its own peculiarities which can not always be covered by rules.
Therefore, your experience and common sense will be your best guide to safety.
Be ever watchful for safety hazards and correct deficiencies promptly.
Use the following safety precautions as a general guide to safe operations:
1. Read the manual thoroughly before operating or working on the equipment.
2. Read and follow any safety instructions in the CATERPILLAR engine operators
manual.
3. Only well trained and experienced personnel should attempt to operate or maintain
this equipment.
4. Never adjust, lubricate or repair the unit when it is in operation, or lifted above
ground level.
5. Never remove, paint over or cover warning or safety labels. If labels become
damaged or unreadable, replace immediately.
6. All personnel should wear approved safety clothing, including HARD HATS,
SAFETY SHOES, SAFETY GLASSES and HEARING PROTECTION when in the
vicinity of this machinery.
7. Do not stand any closer to this equipment than necessary when it is in operation.
Parts may loosen and fall. Piling may shatter or break. Never stand under
operating, or elevated, equipment.
8. When maintaining or repairing the equipment, never substitute parts not supplied,
or approved in writing, by J&M.
9. Do not weld, or flame cut, on this equipment.
10. Never use or store flammable liquids on or near the engine.
11. Insure that all lifting equipment, including cranes, wire rope, slings, hooks, shackles,
etc., are properly sized for the worst case loads anticipated during operations.
12. If there are any questions about the weights, specifications, or performance of the
unit, contact J&M before handling or operating the equipment.
13. If the equipment is to be used for anything other than driving plumb piles, contact
J&M before using the unit.
14. Check wire rope clips for tightness, and check wire ropes for wear, daily.
15. Insure that ground vibrations will not damage or collapse adjacent structures or
excavations.
II-1
MODEL 220
HYDRAULIC
IMPACT HAMMER
II. PREPARATION FOR OPERATION
B. SAFETY PRECAUTIONS (CONTINUED)
16. Remove all tools, parts and electrical cords before starting the unit.
17. When operating in an enclosed area, pipe exhaust fumes outside. Continued
breathing of exhaust fumes may be fatal.
18. When servicing batteries, do not smoke or use open flames in the vicinity. Batteries
generate explosive gas during charging. There must be proper ventilation when
charging batteries.
19. When filling fuel tank, do not smoke or use open flame in the vicinity.
20. If abnormal equipment operation is observed, discontinue use immediately and
correct the problem. Do not leave the equipment control pendant (radio control)
unattended.
21. Store oily rags in approved containers, and away from engine exhaust system.
22. Make sure that the hammer is OFF before starting the power unit engine.
23. Do not adjust, or set, hydraulic pressures higher or lower than those specified in the
manual.
24. Never operate this equipment with hydraulic hoses that are damaged or “kinked”.
Replace damaged hoses immediately.
25. Do not lift, or support, hydraulic hoses with wire rope slings.
26. Never attempt to connect quick disconnects when the power unit is running.
27. Do not pull on, or attempt to move equipment, with hydraulic hoses.
28. Do not attempt to locate hydraulic leaks with your hands. High pressure hydraulic
leaks can penetrate the skin, causing severe damage, blood poisoning and
infection. Do not attempt to repair leaks while the equipment is in operation.
29. Do not attempt to tighten, or loosen, fittings or hoses when the machine is in
operation.
30. Power unit must always be placed on level, stable, ground.
31. Do not remove power unit heat shields, or operate power unit without heat shields.
Severe fires may result.
32. A properly maintained fire extinguisher, suitable for oil fires, must be kept in the
immediate vicinity of equipment operations.
33. When moving or transporting this equipment, insure that the vehicle or vessel is of
sufficient capacity to handle the load, and that the equipment is properly tied down.
34. Always block the ram, to prevent movement during transport.
35. When moving or transporting this equipment, be sure that quick disconnect dust
caps are tight, and that cap safety cables are in place. Be sure that all equipment
parts are tight, or properly secured, before shipment. Unsecured parts may vibrate
loose and fall, during transport, causing injury or property damage.
36. Keep crane boom, piles, leads, wire rope and other equipment at least 15’ (5M)
from electrical power lines, transformers and other electrical equipment, or at such
distance as required by applicable safety codes.
II-2
MODEL 220
HYDRAULIC
IMPACT HAMMER
II. PREPARATION FOR OPERATION
B. SAFETY PRECAUTIONS (CONTINUED)
37. Rounded or damaged bolt heads or nuts should be replaced so that proper torque
values may be obtained. Proper torque values are necessary to prevent parts on
this equipment, leads and crane boom from loosening and falling. Refer to Torque
Chart, in the manual, for proper values.
38. Always be sure that the crane line is aligned with the centerline of the pile. Do not
side load crane boom or hammer. Dangerous crane boom, or hammer, damage
may result.
39. Use tag line to control hammer whenever possible.
40. When driving “batter” piles, insure that the leads, and crane boom, have sufficient
bending strength to handle the worst case load. Consult J&M.
41. Do not attempt to service hydraulic accumulators without first venting all high
pressure gas from these units.
42. Pre-charge accumulators only to pressures specified, and only with Nitrogen gas.
43. Pile ends must be cut square, and flat, before cushion material and/or drive cap are
placed onto pile.
44. Use only pile caps that are correctly sized for the type, cushion material and pile
size being driven.
45. Before starting driving operations, check that the hammer, striker block and pile cap
are properly aligned with the centerline of the pile. Dangerous lateral forces,
generated by misalignment, may damage hammer or break piling, with resultant
hazard from falling objects.
46. Stay well clear of ram point, pile cap and striker block. Fragments of metal may be
broken, or spalled off, and ejected at high speed.
47. Large amounts of heat are generated, within cushion material, during driving.
Cushion material, or flammable materials in the vicinity, may ignite. Personnel
should use extreme caution, and avoid contact with ram point, cushion material and
drive cap.
48. It is the responsibility of the contractor to determine what, if any, hazardous
materials, or gases, may be emitted from cushion materials due to deterioration,
decomposition, excessive temperature or combustion. Contact the cushion
material manufacturer.
49. Frequently inspect and tighten the wire ropes, wire rope clips and pins that secure
the drive cap to the hammer. Replace these components at the first sign of wear or
fatigue. Tighten clips regularly.
REMEMBER, SAFETY IS EVERYONE’S BUSINESS.
II-3
MODEL 220
HYDRAULIC
IMPACT HAMMER
II. PREPARATION FOR OPERATION
C. HANDLING
Safe handling practices will insure protection of both the hammer and personnel
working near the unit. Do not pick up the hammer by the guide columns. Doing so
can scratch the surface finish on the columns and damage the ram bearings.
To lift hammer horizontally (See Fig 1):
The hammer is designed to be picked up by the lead guide rails. Use shackles at
each of the four lifting holes provided in the lead guides to attach the four lifting
cables. Alternately, the hammer can be picked up using the lifting sheave and a pin
through the cable ears in the bottom plate. Ensure that the lifting cables are
properly sized for the hammer weight and sling angle.
Always block the ram, to prevent movement during transport and / or lifting.
FIG 1
II-4
MODEL 220
HYDRAULIC
IMPACT HAMMER
II. PREPARATION FOR OPERATION
D. CONNECTING CRANE LINE TO HAMMER
Connect the crane line directly to the hammer using the lifting sheave. The
hammer is designed to be used with a two-part line. If a single-part line is desired,
the sheave can be replaced with a sleeve p/n 160777.
To lift the hammer to a vertical position, first remove the rope guide bolt and sleeve.
(See Fig 2) Pass the crane wire rope around the lifting sheave and re-attach to
crane boom. Lift hammer to the vertical position. Re-install rope guide bolt and
sleeve.
TEMPORARILY REMOVE ROPE
GUIDE BOLT AND SLEEVE
FIG 2
II-5
MODEL 220
HYDRAULIC
IMPACT HAMMER
II. PREPARATION FOR OPERATION
E. ATTACHMENT OF LEAD GUIDES
The hammer is usually shipped with lead or spud guides already in place. If they
are not attached, bolt them into place at the sides of the hammer using the twenty
bolt holes provided on each side of the hammer.
With fixed leads, it is sometimes convenient to stand the hammer in the leads prior
to attachment of the back lead guides.
The lead guide attachment bolts should be properly torqued, using the lock washers
provided, to prevent their coming loose. Torque 1.25-7UNC SHCS to 1,600 Ft-lbs
(221.1 Kg-M).
Do not weld on hammer.
F. ATTACHMENT OF DRIVE CAP (See Fig. 3)
To attach drive cap: Set drive cap insert [11] on dunnage or firm ground. Set drive
cap base [4] (DCB-2 for 32" leads) onto drive cap insert. Attach with wire rope
through two holes provided.
Place 2"(50mm) thick and 22 1/2”(571mm) diameter cushion material [8] into top of
DCB-1 drive cap base (2”(50mm) thick and 25”(635mm) diameter for DCB-2 drive
cap base). Place 1/2”(13mm) thick aluminum plate [7] on top of cushion material.
This plate holds the cushion material in place if it fractures during driving.
Place the 9 1/2” (243mm) thick tapered steel striker block [3] on top of the
aluminum plate
Place the recoil dampener [9] around the top of the striker block.
Set the hammer onto the assembled drive cap set-up. The tapered striker block fits
inside the bottom of the hammer and will lift the ram [1] as the hammer is lowered
onto it. The hammer base plate [2] should sit squarely on the recoil dampener.
Attach the drive cap to the hammer with 3/4”(19mm) wire rope [10]. Insert bolt [6]
through the holes in the cable ears on hammer base plate [2] to keep the
3/4”(19mm) wire rope [10] in place. Secure bolt [6] with the locking nut provided
and fully tighten. Provide enough slack in the wire rope so that, when the hammer
is lifted, 1”-2” (25-50mm) of space should exist between the bottom of the hammer
and the recoil dampener.
II-6
MODEL 220
HYDRAULIC
IMPACT HAMMER
II. PREPARATION FOR OPERATION
1
3
10
4
32” LEADS
1 Ram SAME
2 Hammer Base Plate SAME
3 Striker Block SAME
4 Drive Cap Base 700006
5 Bumper SAME
6 Bolt & Nut SAME
7 Alluminum Plate 700004
8 Cushion 700002
9 Recoil Dampener SAME
10 3/4" Wire Rope
11 Drive Cap Insert
G. MOUNTING HAMMER IN LEAD
To slide the hammer into swinging leads, in horizontal position, pick up hammer as
described in Section II-C.
For vertical installation into leads, first attach the crane line to the hammer as
described in Section II-D. and lift hammer carefully into vertical position. Position
leads over the hammer and lift the hammer into the lead guide rails.
Alternately, remove the rear lead guide angles from the hammer. Position the
hammer on the lead guide rails and re-install the rear guide angles. Be sure to
torque the guide angle attachment bolts per Section II-E.
5
6
2
9
7
8
11
FIG 3
II-7
MODEL 220
HYDRAULIC
IMPACT HAMMER
II. PREPARATION FOR OPERATION
H. CONNECTION OF HYDRAULIC HOSES
Connection of hoses at the Power Unit
The hammer is connected to the power unit by four hydraulic hoses.
(See Fig. 4)
CAUTION: The power unit must be shut down during connection of the hydraulic
hoses.
The hoses connect to the power unit with quick-disconnect couplings. The hose
couplings are arranged so that the hoses can only be connected in the correct
manner.
Clean the couplings with a lint-free cloth before making connections.
Make sure that the couplings are fully run up (tightened). They should be firmly
hand tight. If wrenches are used, be careful not to over-tighten. Pipe wrenches are
not recommended.
Connection of hoses at the Hammer
The Model 220 is normally shipped with the hoses attached to the hammer. If the
hoses have been shipped separately, they must be connected to the hammer.
Figure 4 shows the correct hose arrangement.
After the hoses have been connected, and tightened, to their respective fittings,
they must be secured in the hose clamps on the hose bracket (See hammer
assembly drawing in the PARTS LIST section). Be sure to leave enough slack in
the hoses, above the hose clamps, to permit 3-4” (76-101mm) of downward
movement by the hose clamp shock mounting elastomer.
II-8
MODEL 220
HYDRAULIC
IMPACT HAMMER
II. PREPARATION FOR OPERATION
I. FILLING THE HAMMER PRESSURE HOSE
The hammer is normally shipped with the hammer hydraulic hoses full of oil and the
unit may be used immediately. However, if the pressure hose has been removed
from the hammer, the hose may need to be filled with hydraulic oil prior to full speed
operation. It is not necessary to fill the return hose with oil.
Read SECTION III - OPERATING INSTRUCTIONS
Start and warm-up the engine in accordance with SECTION III C. With the engine
warmed-up and running at 1500 rpm, turn and hold the hammer switch to the
REVERSE position. The hoses will fill with oil in approximately two minutes. Do
not engage any other switches on the control pendant during this two minute
period.
PRESSURE HOSE (1 1/4")
RETURN HOSE (1 1/2")
EXTEND CYLINDER SHORTEN STROKE HOSE (3/8")
RETRACT CYLINDER LENGTHEN STROKE HOSE (3/8")
FIG 4
II-9
MODEL 220
HYDRAULIC
IMPACT HAMMER
II. PREPARATION FOR OPERATION
J. BLEEDING THE VARIABLE STROKE CYLINDER LINES
The hammer is normally shipped with the two 3/8” hoses full of oil and the unit may
be used immediately. However, if the hoses have been removed from the hammer,
the hoses may need to be filled with hydraulic oil prior to driving operations.
Remove the hose from its fitting at the cylinder (P/N 160817) retract end. Place
and hold the end of the hose in an adequate container or bucket.
Read SECTION III - OPERATION INSTRUCTIONS
Start and warm-up the engine in accordance with SECTION III C. With the engine
warmed-up and running at 1000 rpm, turn the clamp switch, on the control pendant,
to the CLOSE position. Oil should start flowing from the hose within 20 seconds.
When the flow of oil is bubble free, return the clamp switch to the OFF position, and
stop the diesel engine.
Reconnect and tighten the hose to the cylinder.
Remove the hose from its fitting at the cylinder extend end. Place and hold the end
of the hose in an adequate container or bucket.
Start and warm-up the engine in accordance with SECTION III C. With the engine
warmed-up and running at 1000 rpm, turn the clamp switch, on the control pendant,
to the OPEN position. Oil should start flowing from the hose within 20 seconds.
When the flow of oil is bubble free, return the clamp switch to the OFF position, and
stop the diesel engine.
Reconnect and tighten the hose to the cylinder.
K. VARIABLE STROKE CYLINDER PRESSURE
The variable stroke cylinder pressure should be approximately 1500 PSI (103 Bar).
If the J&M Model 325 power unit is always used with the Model 220 hydraulic
impact hammer, the variable stroke cylinder pressure should already be properly
set. Whenever a new job is started, or when the 325 power unit has been used to
drive a vibratory driver/extractor, or when an alternate power unit is to be used, the
variable stroke cylinder pressure should always be checked before starting driving
operations.
Read SECTION III - OPERATING INSTRUCTIONS.
II-10
MODEL 220
HYDRAULIC
IMPACT HAMMER
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